OK, so maybe you aren’t interested in making your own toys, cellphone cases, or glow-in-the-dark Christmas decorations. How about a brake drum?

Until now, 3D printing has been a polymer affair, with most people in the maker community using the machines to make all manner of plastic consumer goods, from tent stakes to chess sets. A new low-cost 3D printer developed by Michigan Technological University’s Joshua Pearce and his team could add hammers to that list. The detailed plans, software and firmware are all freely available and open-source, meaning anyone can use them to make their own metal 3D printer.

Pearce is the first to admit that his new printer is a work in progress. So far, the products he and his team have produced are no more intricate than a sprocket. But that’s because the technology is so raw. “Similar to the incredible churn in innovation witnessed with open-sourcing of the first RepRap plastic 3D printers, I anticipate rapid progress when the maker community gets their hands on it,” says Pearce, an associate professor of materials science and engineering/electrical and computer engineering. “Within a month, somebody will make one that’s better than ours, I guarantee it.”

Using under $1,500 worth of materials, including a small commercial MIG welder and an open-source microcontroller, Pearce’s team built a 3D metal printer than can lay down thin layers of steel to form complex geometric objects. Commercial metal printers are available, but they cost over half a million dollars.

His make-it-yourself metal printer is less expensive than off-the-shelf commercial plastic 3D printers and is affordable enough for home use, he said. However, because of safety concerns, Pearce suggests that for now it would be better off in the hands of a shop, garage or skilled DIYer, since it requires more safety gear and fire protection equipment than the typical plastic 3D printer.(more)